The potential and trends of foam glues

In the last few years, foam bonding has become an increasingly demanding business. Many key application fields of foam – foam converting and upholstery, mattress manufacturing and automotive – face multiple challenges, such as cost pressure, workspace contamination and rising consumer demands. In this article, we present solutions that work for any of these industries.

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A key issue in all industries is the increasing need for sustainable products. Many consumers as well as political regulations demand a more and more eco-friendly production.

As a pioneer in water-based, sustainable adhesives for the foam industry, SIMALFA® can support you in this endeavor.

The idea for SIMALFA® arose as a response to the commonly held beliefs at the time: It was not possible to produce a solvent-free adhesive for foam bonding with an instant tack.

We have successfully proven the opposite and since the invention of the SIMALFA® line in the 1990s, we have been producing water-based, solvent-free adhesives without environmentally harmful VOC. Additionally, the SIMALFA line is distinguished by excellent bonding properties, such as fast drying behavior, a high instant tack as well as fast and easy processing.

Due to this innovative thinking, we have become one of the global market leaders for foam glues and help many companies face their general and individual challenges.

To tackle cost pressure, overspray and more, we offer a variety of products with different properties, such as fast drying, overspray-free application, flame-retardance, and excellent bonding with all kinds of materials. In this blog, we would like to present solutions to common situations that arise in manufacturing.

To start off, we have prepared a few articles of general interest on topics such as the benefits of PU foam or the different adhesive types available. Later, we dive into the three industries: mattress manufacturing, upholstery and automotive, and talk about individual topics, challenges, and solutions.

The benefits of PU foam

PU foam (also PUR foam or polyurethane foam) has become an indispensable component of many products. Depending on its exact composition, the texture of the PU foam can vary significantly. In its soft form with a high percentage of air, it is an excellent material for mattresses and upholstering.

With SIMALFA®, PU foam can be bonded with almost every other material and is therefore extremely versatile.

Due to the viscosity of our adhesives, they do not seep into the material. They tack instantly and hold together different materials even when they are under tension. Additionally, the adhesive quantity required is significantly lower than is the case with solvent-based adhesives and even other water-based adhesives, which makes SIMALFA® the most profitable choice.

PU Foam

But how can the glue be applied most efficiently and economically? And what is the proper equipment for my application field?

Find out how to optimize your production with PU foam!

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PU Foam

Adhesive types: The right choices for foam glue in mattress and furniture production and transportation

Adhesives play a crucial role in manufacturing industries such as foam converting, upholstered furniture, automotive, or mattress manufacturing. In view of the wide range of needs, the right type of adhesive must be chosen based on the requirements of the production process, the materials to be bonded and the application method.

This article offers a brief overview of solvent-free solutions.

In general, one can differentiate between solvent-based and solvent-free adhesives. Whereas solvent-based glue was highly relevant for adhesive applications in the past, today, solvent-free solutions provide healthier environments for users as well as better performance. Another differentiating factor is whether the adhesives are applied as one or two components. Both approaches have their advantages. We will show you how you can find the perfect adhesive for your individual needs!

Adhesive Types

The right choices for foam-bonding glue in mattress and furniture production as well as transportation.

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Adhesive Types

Adhesive application for foam glue

The quality of an adhesive does not just lie in a strong and long-lasting bond.

There are further criteria to define its value and suitability for a manufacturing process, such as the application method or equipment.

Of the two different possibilities – rolling and spraying – to apply adhesive to the workpieces, roller application is most commonly seen in mattress manufacturing because of the fast and even application on the big, flat surface of the mattress foam. Contrary to that, manual spray application is more often used in the upholstering and foam converting industry. Spray application is advantageous for smaller and variable foam pieces because of its flexibility.

Adhesive Application

But how do you convey the adhesive from its storage container to the workplace? Do I need a complicated installation system? No, this process has never been so easy! Find out how to use the force of gravity for adhesive delivery.

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Adhesive Application

Solutions for mattress manufacturing

Mattresses are manufactured from a wide range of materials, such as latex, polyether, PU foam, viscoelastic memory foam, cover materials, felt, coir and spacer fabrics that all need to be bonded properly.

The high quality of your mattresses can therefore only be guaranteed with the proper adhesive.

But as we all know, there are several other challenges in today’s mattress manufacturing industry: The increasing number of online sales requires fast and efficient production of high quantities – this has implications for the material and the adhesives as well as the application method and the equipment.

One option to speed up your production is to use a force-dried adhesive that tacks instantly. Further handling can continue immediately, even if the next step is roll packing.

Mattress manufacturing

But how fast is fast? And what will happen to the quality of the mattress?

Find out more about adhesive solutions for mattress manufacturing that will blow your mind!

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Mattress manufacturing

Improved efficiency with fast-drying adhesives

In the manufacturing of mattresses, efficiency of production is key for a profitable business considering that the drying process after gluing can be a significant cost factor.

It has now been nearly 20 years since SIMALFA® water-based adhesives became suitable for roller application and therefore the innovative solution that superseded hotmelts and resin adhesives. As we have always been on the front lines of research and development of high-quality adhesives, we are proud to offer a wide spectrum of products designed to optimize manufacturing processes worldwide.

As an alternative to the force-drying adhesive mentioned above, we also offer naturally drying adhesives such as SIMALFA® 3031, which stands out thanks to the small application amount required and is, therefore, a cost-efficient solution.

Fast Drying

With perfectly adjusted roller applicators, no material is wasted, and the process can be continued immediately.

Let us show you how to boost the efficiency of your production process!

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Fast Drying

How rolled mattresses optimize your production

The size and weight of mattresses pose a challenge during production, storage, and especially delivery. With special packing methods, it is possible to ship mattresses conveniently and inexpensively in rolled form. The compressing and rolling also saves packaging material such as plastic foil. To start producing rolled mattresses successfully, some considerations need to be made first. It starts with choosing the suitable raw materials, continues with the gluing process, and ends with the right kind of roll packaging.

To roll pack the mattress, several procedures are possible. Inline productions often include a packaging machine at the end, but these machines can also be purchased separately. Normally, the mattress is pressed, vacuumed, and packed into an airtight foil while flat.

But will the glue be able to withstand this pressure? And will the mattress unroll properly? If you choose SIMALFA®, the answer is a clear Yes!
How rolled mattresses optimize the logistics of your products

The size and weight of mattresses is a challenge during production, storage, and especially delivery. With special packing methods, it is possible to ship mattresses conveniently and inexpensively in rolled form.

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How rolled mattresses optimize the logistics of your products

The importance of mattress recycling

The entire mattress industry is seeing an increasing ambition from both manufacturers and consumers to improve the sustainability performance.

A massive reduction in CO2 emissions is targeted by the industry, which requires an increased level of recycling.

Different recycling procedures are already possible, but the development of solutions allowing the fully circular processing of raw materials is still in progress.

One wide-spread challenge of recycling mattresses is toxic ingredients. The foam itself does usually not contain anything that might turn toxic to the environment during the recycling process. But what about the adhesives or other materials used? Because we view recycling as essential, all SIMALFA® products are tested for contaminants and do not pollute the environment during mechanical or chemical recycling processes. But what becomes of the old foam?

Mattress recycling

Read more about the potential second life of your mattress!

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Mattress recycling

Roller coating in mattress manufacturing

In mattress manufacturing, adhesive application with a roller coater is beneficial for various reasons, such as efficient and accelerated production, precise application, and a clean work environment. SIMALFA® was a pioneer in the development of roller coating machines for adhesive application.

The efficiency and success of roller coating depend on the equipment used, the adhesive itself and proper adjustment of the machine.

If the roller can be adjusted precisely, the application quantity of the adhesive can be reduced to a minimum and the whole process is extremely economical. Of course, SIMALFA® will assist you in carrying out the installation and optimizing the process!

Roller Coater

Here we show you how to make your mattress manufacturing more profitable.

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Roller Coater

Tackling overspray, production delays and cost pressure in upholstering

In the upholstering industry, the efficiency of the production process is a key factor to keep up with the competition.

There is little room for delays due to slow drying or clean-up of messes caused by overspray.

One solution for these problems lies in the selection of the proper adhesive and optimizing the bonding process. Water-based adhesives constitute a high-quality alternative to the common solvent-based glues. The lack of toxic solvents makes the product eco-friendlier while innovations in product development and equipment technology eliminate overspray. High instant tack and short drying times improve the efficiency of the production process further.

Upholstering

Here you can find out how to tackle overspray, glue efficiently under tension and improve the sustainability of your product!

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Upholstering

Contact adhesives for foam glue

In the upholstering industry, foam glues are often exposed to high tensile forces while the adhesive is still in in the process of drying. The challenges associated with gluing the bent edges of the foam at the backrest of a chair or the bent upholstery of a couch are well known.

In such cases, contact adhesives enable a strong instant tack to keep the pieces together despite the tension.

A contact adhesive is applied to both pieces that are to be joined, which reinforces the instant tack. We know that in some situations, one-sided application adhesives are a must. We therefore also offer adhesives that can be applied on just one side, still tack instantly, and are long-lasting. Due to the lower application quantity and easy handling, they make the production process more efficient.

Wet Contact Adhesives for gluing foam

But which option is right for me? Find out about the possibilities you have!

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Wet Contact Adhesives for gluing foam

The trustworthy ally in the automotive industry

Due to the increasing number of regulations to protect the environment, each step in the production of automobiles needs to be reconsidered.

Although they seem like a small component of the whole vehicle, adhesives are a key contributor to various parts of this industry (seats, headliners, interiors, door panels, etc.).

By using a water-based, eco-friendly adhesive, environmental regulations are much easier to comply with. In addition, there are different requirements concerning the safety of the passengers. Adhesives are what holds the whole vehicle together, especially at high speeds and under large loads. In case of an accident, stability and fire protection are two of the most important features.

But how can I achieve the flexibility required to fix blowholes? With the proper application system. And how do fulfil fire safety? With our flame-retardant adhesives. Get to know more solutions for your problems!

The trustworthy ally in the automotive industry

Due to the increasing number of regulations to protect the environment, each step in the production of automobiles needs to be reconsidered.

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The trustworthy ally in the automotive industry

As you have seen, solutions can be found for (almost) every issue in the foam bonding industry. Of course, we cannot turn the world upside down – but we can try to make it a little bit better. And therefore, we give our best every single day to make production easier, faster and more sustainable. If you have any questions concerning our solutions, our company or anything else, please do not hesitate to contact us!

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